Wire-coiling machine with differential drive



P 6, 1966 D. P. WHITACRE 3,270,978

WIRE-GOILING MACHINE WITH DIFFERENTIAL DRIVE 4 Sheets-Sheet 1 Filed Oct. 28, 1964 Pia 3.

INVENTOR. fld/W/fi IVA 074666 Sept. 6, 1966 D. P. WHITACRE 3,270,973

WIRE-COILING MACHINE WITH DIFFERENTIAL DRIVE Filed 061;. 28, 1964 4 Sheets-Sheet 2 WIRE-COILING MACHINE WITH DIFFERENTIAL DRIVE Filed Oct. 28, 1964 Sept. 6, 1966 o. P. WHITACRE 4 Sheets-Sheet 5 INVENTOR. M41410 2 WfiWZC Sept. 6, 1966 D. P. WHITACRE 3,270,978

WIRE-COILING MACHINE WITH DIFFERENTIAL DRIVE Filed Oct. 28, 1964 4 Sheets-Sheet 4 United States Patent 3,270,978 WIRE-COILING MACHINE WITH DIFFERENTIAL DRIVE Donald P. Whitacre, 1013 N. Margarita Ave, Alhambra, Calif. Filed Oct. 28, 1964, Ser. No. 407,103 9 Claims. (Cl. 242-82) This invention relates to an improved wire coiling and packaging machine. Conventional machines for coiling and packaging wire are of two general types: the first employs a stationary block or capstan on which wire is Wound by means of a rotating flyer; the second uses a rotating block or capstan, and the flyer is replaced by a stationary support for wire-carrying pulleys.

The present invention is directed to a wire-coiling machine in which both the block and the flyer are mounted to rotate about a common axis, and wherein a differential drive mechanism is provided for rotating the block and for rotating the flyer at varying relative speeds. The purpose is to provide a novel form of coiling machine on which several types of coils may be produced, as desired. Thus, the coiling machine of this invention readily produces coils of wire in any one of three types: (a) a random-pattern coil of substantially concentric loops, (b) a coil in which the loops are all of the same diameter but are circumferentially staggered, and (c) a coil comprising a series of layers, each layer being spirally wound, alternate layers comprising inward-wound spirals and outward-wound spirals. Only the type (-b) coil requires a turntable to receive the coil. Wire coils of type (c) are very compact and contain a maximum amount of wire for a given diameter and length of wire coil.

The principal object of this invention is to provide a novel form of wire-coiling machine in which the wire convolut-ion diameter in the coil may be readily changed without changing the diameter of the capstan and without changing the linear speed of wire drawn into the machine. Another object of this invention is to provide a novel form of wire-coiling apparatus for making type (c) coils as above described and without requiring the use of a rotary turntable for supporting the coil, such apparatus also being readily capable of making type (a) coils if desired, as described above, and capable of making type (-b) coils if a turntable is provided. Another object is to provide a device of this type having a rotary block and rotary flyer mounted for concentric turning movement and driven by a differential drive mechanism. Another object is to provide novel control means for the differential drive mechanism.

Other and more detailed objects and advantages will appear hereinafter.

In the drawings:

FIGURE 1 is a side elevation showing a preferred embodiment of this invention.

FIGURE 2 is a top view of a random-pattern coil which may be produced by the device of FIGURE 1.

FIGURE 3 is a plan view of a second form of coil which may be produced by the machine. In this coil, the loops are of the same diameter but circumferentially staggered. The coil is supported on a turntable.

FIGURE 4 is a diagrammatic illustration of a third form of coil which may be produced by the machine, the coil comprising a series of layers, each layer being spirally wound and adjacent layers being spiraled inwardly and spiraled outwardly, respectively.

FIGURE 5 is a plan view taken substantially on the lines 55 as shown in FIGURE 1.

FIGURE 6 is a fragmentary detail taken substantially on the lines 6--6 as shown in FIGURE 5.

FIGURE 7 is a sectional elevation taken substantially on the lines 77 as shown in FIGURE 5.

FIGURE 8 is a sectional plan view taken substantially on the lines 88 as shown in FIGURE 7.

FIGURE 9 is a side elevation taken substantially on the lines 9-9 as as shown in FIGURE 8.

FIGURE 10 is a sectional detail taken substantially on the lines 1010 as shown in FIGURE 8.

FIGURE 11 is a sectional detail taken substantially on the lines 1111 as shown in FIGURE 8.

FIGURE 12 is a diagrammatic illustration showing the internal construction of the differential drive mechanism.

Referring to the drawings:

The stationary frame generally designated 10 includes the supporting legs 11 and includes a platform 12 supporting a worm gear drive unit 13. This unit 13 contains axial-1y spaced bearing assemblies 14, which rotatably support a hollow, vertical shaft 15. A worm gear 16 (FIGURE 5) is fixed on this hollow shaft 15 and is driven by a worm pinion 17 fixed on the horizontal shaft 18.

A rotary-flyer assembly generally designated 20 includes a hub 21 (FIGURE 7) which is fixed to the lower portion of the vertical shaft 15 by means of key 22 and retainer ring 23. The rotary-flyer assembly 20 also includes a horizontal arm 24 fixed to the hub 21 by suitable fastenings 25. Rotatably mounted on spaced bearings 26 on the hub 21 is the capstan or block 28. The block 28 and the rotary-flyer assembly 20 are thus both mounted for turning movement about the axis of the hollow vertical shaft 15. A driven sprocket 30 is fixed to the block 28 by suitable fastenings 31 and is driven by chain 32 from driving sprocket 33. This sprocket 33 is fixed on the shaft 34 projecting downward from. Worm drive unit 35. The driving shaft of this Worm drive unit 35 is shown at 36. From this description it will be under stood that the rotary-flyer assembly 20 is driven from the power-input shaft 18 of the worm drive unit 13, and the block 28 is driven by the power-input shaft 36 of the worm drive unit 35.

A differential drive mechanism generally designated 40 is provided for driving both the shafts 18 and 36. As

shown in the drawings, this differential drive unit 40 includes a housing 41 rotatably supporting a power-input shaft 42, which projects from both ends of the housing. Housing 41 also supports a driven shaft 43, which is connected by coupling 44 to drive the shaft 36. The housing 41 also supports the driven shaft 45, Which carries pulley 46. This pulley 46 is connected by belt 47 to pulley 48, which is fixed on the shaft 18. The shaft 18 projects from both sides of the worm gear unit 13.

The internal mechanism of the differential drive unit 40 is conventional and as shown in FIGURES 5 and 12 includes a spider 50 fixed to the shaft 42 and carrying rotatable bevel gears 51. These bevel gears 51 mesh with bevel gears 52 and 53, chain-connected to driven shafts 43 and 45, respectively. From this description, it will be understood that when torque is applied to the driving shaft 42, gearing within the housing 41 acts to apply torque to the driven shafts 43 and 45. The relative rotary speeds of these driven shafts is controlled in the manner described below. The driving shaft 42 receives power from the pulley 55, driven by belt 56 from the driving pulley 57, and the driving pulley 57 is fixed on the output shaft 58 of gear-reduction unit 59, forming a part of the prime mover 60. This prime mover 60 preferably includes a variable-speed electric motor 61 having a control shaft 62 for regulating the speed of the output shaft 58. A crank handle 63 is fixed to this -speed-control shaft 62 and placed in a conveniently accessible position in an exposed location on the frame 10. mover is supported on the platform 12.

Means are provided for controlling the relative rates of rotation of the driven shafts 43 and 45 of the differential drive unit 40, and as shown in the drawings this means includes a variable speed drive unit 65, supported on the platform 12 and driven by belt 66 on pulleys 67 and 68. The pulley 67 is fixed to the power-input shaft 42, which extends through the differential drive unit 40. The input shaft 70 fixed to the pulley 68 rotates at constant speed according to the speed setting of the prime mover 60. The output shaft 71, however, to which pulley 72 is fixed, turns at a speed and in a direction regulated by the control shaft 73. The internal construction of the variable speed unit forms no part of the present invention, it being only essential that the device 65 vary the speed and direction of the driven shaft 71 relative to the driving shaft in accordance with the rotational position of the shaft 73. It has been found that the device sold by Cleveland Worm and Gear Division, Eaton Manufacturing Company, Cleveland, Ohio, under the mark Speed Variator gives satisfactory results. That device provides variable speeds over a wide range in stepless increments. The pulley 72 fixed on the variable speed output shaft 71 is connected by belts 75 to pulley 76 fixed on shaft 77. A coupling 78 connects the aligned shafts 77 and 18. Accordingly, the power for rotating the shaft 18 comes from pulley 48 via belt 47 and the differential gearing within the differential drive unit 40, but the speed of rotation of the shaft 18 is controlled by means of the variable speed unit 65. This will be apparent from a consideration of the diagram of FIGURE 12. Power supplied to shaft 42 drives the spider 50 and the bevel gears divide the torque equally between the driven shaft 43 which drives the rotary-flyer assembly 20, and the driven shaft 45 which drives the block 28. If there were no speed regulating connection (and none is shown in FIGURE 12) then either of the driven shafts 43 or 45 might be turned while the other remains at rest, depending on the load driven by each of these shafts. When the speed regulating connection 66, 65, 75, 77 and 78 is applied between the driven shaft 42 and the shaft 18 driven by shaft 45 through belt 47, the relative speeds of the shafts 43 and 45 are fixed, for any one setting of the variable speed device 65.

The speed control shaft 73 has a pulley 80 fixed thereto and driven by means of belt 81 from a drive pulley 82. This drive pulley 82 is rotated by means of a small electric motor 83 and speed-reduction unit 84. The belt 81 also passes around pulley 86 fixed on shaft 87, having a threaded portion 88. A traveling nut assembly 89 is mounted on the threaded portion 88 and moves longitudinally when the shaft 87 rotates. As shown in FIG- URE 6, a projection 90 on the assembly 89 slides along the stationary guide rod 91 to prevent rotation of the assembly 89. A switch-actuating arm 92 pivoted on the assembly 89 engages adjustable limit stops 93 and 94 to define the limits of travel of the assembly 89. Elec- The prime trical switches, not shown, are provided on the assembly 89, and these are connected by wiring 95 and 96 to control operation of the electrical motor 83. Thus, when the switch-actuating arm 92 of the traveling nut assembly 89 engages the limit stop 94, the direction of rotation of the motor 83 is reversed to cause the shaft 87 to reverse direction of rotation and cause the traveling nut assembly 89 to reverse its directtion of longitudinal travel. Similarly, when the switch-actuating arm 92 engages the limit stop 93, the direction of rotation of the motor 83 is again reversed.

When the speed-control shaft 73 is stationary, the speed ratio between the driving shaft 70 and the driven shaft 71 of the unit 65 remains constant. When the motor 83 is operated, the speed-control shaft 73 is turned at a constant speed in one direction until the traveling-nut assembly 89 reaches the end of its travel in one direction, thereby reversing the direction of rotation of the motor 83. The speed-control shaft 73 is then turned in the other direction until the assembly 89 reaches the other end of its travel, at which time the direction of turning of the speed-control shaft 73 is again reversed. This has the elfect of gradually increasing and decreasing the speed of the output shaft 71 and hence the speed of the rotary-flyer assembly 20 fixed to the hollow shaft 15.

A pulley 100 receives wire W under tension from a source, not shown, and directs it down through the hollow center of the shaft 15. The rotating arm 24 of the fiyer assembly 20 carries a second pulley 101 which receives the stretch of wire W passing through the hollow shaft 15 and directs the wire through. the killer-block assembly 102, which functions to remove memory of the wire. The wire W then passes around the third pulley 103, which is also mounted on the rotating arm 24. As shown in FIGURE 8, the wire from the third pulley 103 then contacts the drum surface 104 of the block 28 through a short are and then passes around the idler pulley 107, also mounted on the rotary arm 24. A cast-controlling roller 108 (FIGURE 8) is mounted for radial adjustment on the arm 24 and serves to impart any necessary reverse bend to the wire W in order that it may later fall by gravity from the drum surface 104 of the block 28 having the desired circular cast. Adjustment of the radial position of the idler 108 on the arm 24 is accomplished by rotating the starwheel 109 to cause the nut 110 to travel along the threaded shaft 111. The idler 108 is carried on the nut 110. The wire W then passes around the drum surface 104 of the block 28 to form several wraps, the first wrap or convolution lying adjacent the flange 105 (FIG- URE 7) at the upper end of the drum surface 104. The starwheel 109 may be adjusted without stopping the machine. This is accomplished by turning the exposed handle 157 and the horizontal shaft 158 (FIGURE 8), secured thereto, thereby swinging one of two lugs 159 or 160 into the path of travel of the starwheel 109 as it rotates with the flyer assembly 20. This mechanism is described and claimed in my copending application for Coil Winding Machine, Serial No. 328,951, filed December 9, 1963, now Patent No. 3,214,111, issued October 26,1965.

A splitter roller has a peripheral groove 116 for reception of the wire W, and this roller is adjustably positioned by means of the threaded rod 117 and arm 118, to hold it in contact with the drum surface 104 of the block 28 at the desired height. Pressure of the roller 115 against the drum surface 104 is developed by means of the thumb screw 119. The arm 118 is pivotally mounted at 120 on the support arm 24. A similar grooved splitter roller 121 is mounted on pivot arm 122 and maintained in contact with the drum surface 104 by means of the thumb screw 123. Both of the splitter rollers 115 and 121 engage the last convolution of wire on the drum 104 before it drops by gravity to form a coil C.

Interposed between the location of the splitter rollers 115 and 121 and positioned to contact the lowermost convolution of wire passing through the grooved rollers 115 and 121 is a pressure roll assembly, generally designated 125. Four duplicate rollers 126 are mounted on this assembly between parallel plates 127. A central threaded pivot post 128 supports the plate 127 and is carried on a slide member 129 having a key portion 130 projecting through a slot 131 on the arm 24. A spring 132 extending between the flange 133 and the adjusting screw 134 acts to hold the last convolution of wire W against the drum surface 104 under pressure. Each pressure roller 126 has two grooves, so that when wear occurs after a period of use the wire W may be transferred to the other groove. Moreover, two pairs of rollers 126 are provided in order to double the service life.

The arrangement of pulleys shown in the drawings produces a left-hand helix in the coil C. When it is desired to produce a coil C having a right-hand helix, the rotary flyer 20 is turned in the opposite direction, the

pulley 103 is'shifted to the angular mount 140, and the idler pulley 107a is used instead of the idler 107. In such case, the last convolution of wire on the block 28 passes through the splitter roller 115 before descending by gravity to form the coil C.

If the device is to be used for making coils C of the general type shown in FIGURE 2, no turntable is required. The diameter of the coil is determined by the position of the control shaft 73, and this control shaft 73 remains at rest while the block 28 and rotary flyer are driven throughv the differential drive mechanism 40. The speed ratio between the shafts 70 and 71, and hence the speed ratio of the block 28 and rotary flyer 20, remains constant. 1

If the coil of the type shown diagrammatically in FIG- URE 3 is to be made by the machine, no turntable is necessary, but the speed-control shaft 73 is constantly rotated, first in one direction and then in the other, by means of the motor 83 and the adjustable reversing mechanism 88 and 89. When the block 28 and rotary flyer 20 are both turning at maximum speed in the same direction, the diameter of the wire convolution between delivered to the coil is a minimum. Conversely, when the difference in rotary speed of the block 28 and flyer 20 is at a maximum, the diameter of the convolution of wire being delivered to the coil is at a maximum. The median position of the control shaft 73 determines the outer diameter of the coil being formed. Each layer of the coil comprises a spiral, adjacent spiral layers being of opposite hand.

When it is desired to produce a coil of the type shown in FIGURE 4, wherein the loops are all of the same diameter but are circumferentially staggered, the turntable 150 is employed. This turntable is driven by the motor 151 (FIGURE 5), reduction unit 152, and both mounted on the platform 12 and connected to drive the turntable by means of the vertical shaft 153 and driving connection 154. The turntable rotates at constant speed. In forming the type of coil shown in FIGURE 4, it is also necessary to use the convolution control cage shown in my copending application, Serial No. 328,950, filed December 9, 1963. This device serves to shift the convolutions of wire laterally as they descend from the block 28, so that each convolution is eccentrically positioned with respect to the axis of the turntable.

It will be observed that regardless of which type of coil is being formed by the machine, the linear rate of movement of wire W into the machine remains constant. This is true even when producing spiral type of coils, as diagrammatically shown in FIGURE 3, when the block 28 and rotary flyer 20 turn at cyclically varying speeds.

Having fully described my invention, it is to be understood that I am not to be limited to the details herein set forth, but that my invention is of the full scope of the appended claims.

I claim:

1. In a wire-coiling machine, the combination of: a block mounted to rotate about a vertical axis, a rotaryfiyer assembly mounted to rotate about said axis for wrapping wire upon said block, a differential drive device having a first driven member connected to said block and a second driven member connected to said rotary-flyer assembly, said differential drive device having a power input member, means for driving said power input member, and adjustable control means for regulating the speed ratio between said block and said rotary-flyer assembly.

2. In a wire-coiling machine, the combination of: a stationary frame, a block mounted to rotate on the frame about a vertical axis, a rotary-flyer assembly mounted to rotate about said axis for wrapping wire upon said block, a differential drive device having a power input member and two power output members, means connecting one of said power output members to turn said block, means connecting the other of said power output members to turn said rotary-flyer assembly, means for driving said power input me'mber, and adjustable control means for regulating the speed ratio between said block and said rotary-flyer assembly.

3. In a wire-coiling machine, the combination of: a block mounted to rotate about a vertical axis, a rotaryflyer assembly mounted to rotate about said axis for wrapping wire upon said block, a differential drive device having a first driven member connected to said block and a second driven member connected to said rotary-flyer assembly, said differential drive device having a power input member, means for driving said power input member, and means for alternately increasing and decreasing the relative speeds of said block and said rotary-flyer.

4. In a wire-coiling machine, the combination of: a stationary frame, a block mounted to rotate on the frame about a vertical axis, a rotary-flyer assembly mounted to rotate about said axis for wrapping wire upon said block, a differential drive device having a power input member and two power output members, means connecting one of said power output members to turn said block, means connecting the other of said power output members to turn said rotary-flyer assembly, means for driving said power input member, control means for regulating the speed ratio between said block and said rotary-flyer assembly, and means for cyclically operating said control means for alternately increasing and decreasing the relative speeds of said block and said rotary-flyer.

5. In a wire-coiling machine, the combination of: a block mounted to rotate about a vertical axis, a rotaryflyer assembly mounted to rotate about said axis for wrapping wire upon said block, the wire falling by gravity from the block to form a coil beneath the block, a differential drive device having a first driven member connected to said block and a second driven member connected to said rotary-flyer assembly, said differential drive device having a power input member, means for driving said power input member, and means for changing the speed ratio between said block and said rotary-flyer assembly to control the diameter of said coil.

6. In a wire-coiling machine, the combination of: a block mounted to rotate about a vertical axis, a rotaryfiyer assembly mounted to rotate about said axis for wrapping wire upon said block, a differential drive device having a first driven member connected to said block and a second driven member connected to said rotary-flyer assembly, said differential drive device having a power input member, a speed-changing device having a driving shaft and a driven shaft, common means for driving said power input member and said driving shaft, means connecting said driven shaft to one of said driven members, and control means for regulating the speed ratio between said driving shaft and said driven shaft.

7. In a wire-coiling machine, the combination of: a block mounted to rotate about a vertical axis, a rotaryflyer assembly mounted to rotate about said axis for wrapping wire upon said block, a differential drive device having a first driven member connected to said block and a second driven member connected to said rotary-flyer assembly, said differential drive device having a power input member, a speed-changing device having a driving shaft and a driven shaft, common means for driving said power input member and said driving shaft, means connecting said driven shaft to said second driven member, and control means for regulating the speed ratio between said driving shaft and said driven shaft.

8. In a wire-coiling machine, the combination of: a stationary frame, a block mounted to rotate on the frame about a vertical axis, a rotary-flyer assembly mounted to rotate about said axis for wrapping wire upon said block, a differential drive device having a power input member and two power output members, means connecting one of said power output members to turn said block, means connecting the other of said power output members to turn said rotary-flyer assembly, means for driving said power input member, means including a speed-changing device having a control shaft for regulating the speed ratio between'saidgblock and said rotary-flyer assembly, driving means for rotating said control shaft, and adjustable means for cyclically reversing the direction of rotation of said driving means at predetermined intervals.

9. In a wire-coiling machine, the combination of: a stationary frame, a block mounted to rotate on the frame about a vertical axis, a rotary-fiyer assembly mounted to rotate about said axis for wrapping wire upon said block,

a diflerential drive device having a power input member and two power output members, means connecting one of said power output members to turn said block, means connecting the other of said power output members to turn said rotary-fiyer assembly, means for driving said power input member, and control means for determining the speed ratio between said block and said rotary-flyer UNITED STATES PATENTS 2,929,575 3/1960 Kovaleski 242-82 FOREIGN PATENTS 1,179,396 12/1958 France.

985,738 3/ 1965 Great Britain.

FRANK I. COHEN, Primary Examiner.

STANLEY N. GILREATH, Examiner.

N. L. MINTZ, Assistant Examiner. 

1. IN A WIRE-COILING MACHINE, THE COMBINATION OF: A BLOCK MOUNTED TO ROTATE ABOUT A VERTCAL AXIS, A ROTARYFLYER ASSEMBLY MOUNTED TO ROTATE ABOUT SAID AXIS FOR WRAPPING WIRE UPON SAID BLOCK, A DIFFERENTIAL DRIVE DEVICE HAVING A FIRST DRIVEN MEMBER CONNECTED TO SAID BLOCK AND A SECOND DRIVEN MEMBER CONNECTED TO SAID ROTARY-FLYER ASSEMBLY, SAID DIFFERNTIAL DRIVE DEVICE HAVING A POWER INPUT 